U.S. patent number 5,058,406 [Application Number 07/489,875] was granted by the patent office on 1991-10-22 for plate bending machine equipped with a plate clamping manipulator and a plate position detecting device.
This patent grant is currently assigned to Amada Company, Limited. Invention is credited to Salvatore Arghiracopulos, Gianpaolo Prunotto, Franco Sartorio, Francesco Sgandurra.
United States Patent |
5,058,406 |
Sartorio , et al. |
October 22, 1991 |
Plate bending machine equipped with a plate clamping manipulator
and a plate position detecting device
Abstract
A press brake for bending plates. A press brake is provided for
bending plates, including a pair of dies which act in mutual
cooperation to bend a plate, a plate clamping manipulator which
grasps and moves a plate which is to be placed in a scheduled
location with respect to the dies, and a plate position detector
mounted on the press brake in a specified positional relationship
with respect to the dies, for detecting a position of the plate
grasped by the manipulaator, and controlling the manipulator in
response to a signal from the plate position detector.
Inventors: |
Sartorio; Franco (Turin,
IT), Prunotto; Gianpaolo (Turin, IT),
Sgandurra; Francesco (Turin, IT), Arghiracopulos;
Salvatore (Turin, IT) |
Assignee: |
Amada Company, Limited
(JP)
|
Family
ID: |
26329697 |
Appl.
No.: |
07/489,875 |
Filed: |
March 6, 1990 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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302668 |
Jan 27, 1989 |
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Foreign Application Priority Data
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Jan 29, 1988 [IT] |
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67058 A/88 |
Jan 29, 1988 [IT] |
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67059 A/88 |
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Current U.S.
Class: |
72/16.2; 72/422;
72/420; 414/590 |
Current CPC
Class: |
B21D
43/003 (20130101); B21D 43/105 (20130101); B21D
5/0281 (20130101) |
Current International
Class: |
B21D
43/00 (20060101); B21D 43/10 (20060101); B21D
43/04 (20060101); B21D 5/02 (20060101); B21D
043/11 (); B21J 013/12 () |
Field of
Search: |
;72/9,420,461,422
;83/419,269,367,704,708 ;901/24 ;414/590 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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227528 |
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Oct 1987 |
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JP |
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1303210 |
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Apr 1987 |
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SU |
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Primary Examiner: Spruill; Robert L.
Attorney, Agent or Firm: Wigman & Cohen
Parent Case Text
This is a continuation of co-pending application Ser. No.
07/302,668, filed on Jan. 27, 1989, now abandoned.
Claims
What is claimed is:
1. A press brake comprising:
a pair of dies which can act in mutual cooperation to bend a
workpiece having edges;
a manipulator for grasping and moving the workpiece which is to be
placed in an object position with respect to the dies; and
detector means, mounted in a frame of the press brake in a
specified positional relationship with respect to the dies, for
detecting a plurality of points along the edges of the workpiece
provided by the manipulator, thereby detecting a current position;
and
means for controlling the manipulator in response to a signal from
the workpiece position detector means by adjusting the workpiece
edges relative to the detector means so that the workpiece is
positioned in the object position with respect to the dies;
said means for controlling including means for calculating a
spacing between the current position of the workpiece and the
object position of the workpiece for at least two of said plurality
of points along the edges of the workpiece and means for moving the
workpiece so that each of said plurality of points moves toward
each object position by a predetermined distance, the predetermined
distance being determined by multiplying each of the calculated
spacings by a factor which is smaller than one.
2. The press brake of claim 1 wherein the dies have a longitudinal
axis and wherein further the workpiece detector means is a device
provided at the rear of the dies for detecting the workpiece
position in a direction at right angles to the longitudinal axis of
the dies.
3. The press brake of claim 2 wherein the workpiece position
detector means is so constructed as to measure current workpiece
position within a specified range and the manipulator controlling
means is so constructed as to carry out a final positioning at a
mid position in the specified detection range of the detector
means.
4. The press brake of claim 1 wherein the dies have a longitudinal
axis and a side edge section and wherein further the workpiece
position detector means includes a device provided close to the
side edge section of the dies for detecting the workpiece position
along the longitudinal axis of the dies.
5. The press brake of claim 4 wherein the workpiece detector means
is so constructed as to measure current workpiece position within a
specified range and the manipulator controlling means is so
constructed as to carry out a final positioning at a mid position
in the specified detection range of the detector means.
6. The press brake of claim 1, wherein the manipulator includes
jaws for gripping the workpiece, and support means for supporting
the jaws free to move along an axis perpendicular to the
longitudinal axis of the dies and free to rotate within a plane
parallel to and passing through the longitudinal axis of the
dies.
7. The press brake of claim 6, wherein the manipulator further
includes another supporting means for supporting the jaws free to
move along the longitudinal axis of the dies.
8. The press brake of claim 1, wherein the detector means detect at
least three points along the edges of the workpiece.
9. A method of positioning a workpiece with respect to a press
brake, the positioning occurring between current and object
positions comprising the steps of:
inserting the workpiece between dies of the press brake;
positioning the workpiece in a current position with respect to the
dies;
detecting the current positions of a plurality of sections of the
workpiece with respect to object positions thereof;
calculating a first spacing between the current position of the
first section of the workpiece and the object positions of the
same, and calculating a second spacing between the current position
of the second section of the workpiece and the object position of
the same;
moving the workpiece so that each of the sections thereof moves
toward each of the object positions thereof by a predetermined
distance, the predetermined distance being determined by
multiplying each of the spacings calculated above by a factor which
is smaller than one.
10. The method of claim 9, further comprising the step of stopping
the workpiece movement when the spacings between the current
positions and the object positions becomes less than respective
allowable values.
11. The method for positioning a workpiece of claim 9 wherein the
positioning has associated therewith position coordinate which
comprise:
linear coordinates for a point on the workpiece at right angles to
the longitudinal axis of the dies; and
angular coordinates of a specified edge of the workpiece with
respect to the longitudinal axis of the dies.
12. The method of claim 9, wherein one of the current positions of
the workpiece is an average of positions of rear edges of the
workpiece at both sides thereof in the lateral directions of the
press brake, and another one of the current positions of the
workpiece is an inclination angle of the rear edge of the workpiece
with respect to the longitudinal axis of the dies.
13. A press brake comprising:
a pair of dies which can act in mutual cooperation to bend a
workpiece having edges and lying substantially in a workpiece
plane, the dies having a longitudinal axis;
a manipulator for grasping and moving the workpiece which is to be
placed in an object position with respect to the dies, the
manipulator including a single motor for rotating the workpiece
about an axis perpendicular to the surface of the workpiece
positioned in the workpiece plane;
detector means, mounted on a frame of the press brake in a
specified positioning relationship with respect to the dies, for
detecting a plurality of points along the edges of the workpiece
provided by the manipulator, thereby detecting a current position
of the workpiece edges with respect to the detector means;
means for controlling the manipulator in response to a signal from
the workpiece position detector means by adjusting the workpiece
edges relative to the detector means so that the workpiece is
positioned in the object position with respect to the dies; and
the control means calculating spacings DEX and SX between current
positions of the workpiece and the object positions of the
workpiece for two of the plurality of points along the edges of the
workpiece; calculating from the spacings DEX and SX a first
parameter YM substantially representing the mean of the spacings
DEX and SX, and a second parameter ALFA substantially representing
the rotation of the edge of the workpiece about the axis
perpendicular to the surface thereof with respect to the
longitudinal axis of the dies, rotationally moving the workpiece by
said motor so that each of the first and the second parameters
decreases; and stopping the rotational movement of the workpiece
when at least the first parameter YM gets small than a
predetermined value YS.
14. The press brake of claim 13, wherein the control means stopping
the rotational movement of the workpiece when the difference
between the first and the second parameters gets smaller than a
predetermined value and the first parameter YM gets smaller than a
predetermined value.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a plate bending machine, and, in
particular, to a plate bending machine such as a press brake
provided with a manipulator capable of handling a plate which is
subjected to a bending process in a bending machine, and to a plate
bending machine provided with a plate position detecting device
capable of detecting a position of the plate which is being handled
by the manipulator and being subjected to the bending process.
2. Description of the Prior Art
Conventionally, a manipulator has been developed for automatically
handling the workpiece in a plate bending machine such as a press
brake, where a plate bending operation is performed, in order to
automate this process.
A conventional manipulator, which is usually equipped with an
industrial robot, is generally set up in a specified position in
front of the bending process machine. In this type of manipulator
the arm is installed on a support column in a manner to allow both
free vertical and rotary movement and also to provide free
telescopic motion, and rotation. A plate clamping device is
provided on the end of the arm for freely grasping a workpiece.
In a conventional manipulator with the abovementioned
configuration, for the plate clamping device to have a wide range
of movement the arm must be long. Therefore, the overall
configuration results in a large manipulator, which is a drawback.
In addition, the positioning of a plate in the plate bending device
of the plate bending process machine is performed entirely by the
manipulator. It is therefore necessary to construct a
high-precision manipulator to improve the precision of the
positioning of the plate. This leads to the problem of excessively
high production costs.
The inventor of the present invention, with due consideration to
these problem areas, has disclosed in Japanese Patent application
No. Sho-62-313760 an improved manipulator for handling plate
material in a plate bending machine such as the press brake
described. This manipulator grasps the plate material and causes
the clamped plate to rotate through 180 deg with respect to the
plate bending machine. Accordingly, in the case where the plate is
bent in more than one place, successive scheduled bending points
can be provided to the plate bending machine, depending on the
bending stage.
However, in carrying out a high precision bending process in such a
bending machine, it is necessary for the plate to be accurately
positioned with respect to the plate bending machine. In achieving
such accurate positioning by means of the manipulator mechanism
only, the problem arises that the manipulator must be constructed
with an extremely big degree of precision. This, in turn, leads to
the problem of an extremely high cost for the manipulator.
SUMMARY OF THE INVENTION
An object of the present invention is to provide, with due
consideration to the drawbacks of such conventional devices, a
plate bending machine which is capable of carrying out high
precision plate bending even without a high degree of positioning
precision by the manipulator.
This object is achieved in the present invention by the provision
of a plate bending machine comprising a pair of dies which can act
in mutual cooperation to bend a plate, a plate clamping manipulator
which can grasp and move a plate which is to be placed in a
scheduled location with respect to the dies, and a plate position
detecting means mounted on the plate bending machine in a specified
positional relationship with respect to the dies, for detecting a
position of the plate grasped by the manipulator, and means for
controlling the manipulator in response to a signal from the plate
position detecting means.
By means of this configuration in the present invention, the plate
provided by the manipulator is accurately positioned with respect
to the dies.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features, and advantages of the present
invention will become more apparent from the following description
of the preferred embodiments taken in conjunction with the
accompanying drawings, in which:
FIG. 1 is an explanatory drawing showing an embodiment of a plate
bending machine of the present invention.
FIG. 2 is a side elevation of the plate bending machine of the
present invention.
FIG. 3 is a plan view of part of a workpiece clamping device
provided on a manipulator for the embodiment of the plate bending
machine of the present invention.
FIG. 4 is a side sectional drawing of the workpiece clamping device
of FIG. 3.
FIG. 5 to FIG. 9 are explanatory drawings of the action of the
workpiece clamping device of the plate bending machine of the
present invention.
FIG. 10 is a block diagram of a first control device for
controlling the manipulator to position the workpiece in the Y-axis
direction.
FIG. 11 is an explanatory drawing of the positioning action by the
first control device of the embodiment of the present
invention.
FIG. 12 is a block diagram of a second control device for
controlling the manipulator to position the workpiece in X-axis
direction.
FIG. 13 is an explanatory drawing of the positioning action of the
second control device of FIG. 12.
FIG. 14a, b, and c are explanatory drawings of the fabrication of a
box by the plate bending machine of the present invention.
FIG. 15 is a rough explanatory drawing of the bending process for
fabricating the box shown in FIG. 14b.
FIG. 16 is a flowchart of the bending process.
FIG. 17a, 17b is an explanatory drawing showing the method of using
the sensor for positioning the workpiece for a step in FIG. 16.
FIG. 18 is an explanatory flowchart of the steps for positioning
the workpiece in the X-axis direction in FIG. 16.
FIG. 19 is an explanatory flowchart of, the steps for positioning
the workpiece in the Y-axis direction in FIG. 17.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now referring to FIG. 1, a manipulator 3 is mounted on the front
side of a plate bending machine 1 which may be, for example, a
press brake or the like. A magazine 5, in which a plate workpiece
44 is housed, is provided on the side of the plate bending machine
1. In addition, a transport device 7 for transporting a product P
after bending to the next process is provided. The magazine 5 and
the transport device 7 may be of a structure commonly used for such
devices, therefore a detailed explanation is omitted.
The plate bending machine 1, in the same manner as the usual type
of press brake, is provided with an upper frame 9 and a lower frame
11. An upper die 13 is mounted in a freely removable manner on the
upper frame 9. In addition, a lower die 15 mounted on the lower
frame 11.
As is commonly known, in the plate bending machine 1 with this type
of configuration, one of the upper frame 9 and lower frame 11 can
be elevated, and the bending operation of the workpiece 44 is
carried out by the interposition of the workpiece 44 between the
upper die 13 and the lower die 15 and by the subsequent engagement
of the upper die 13 and the lower die 15.
Further, details have been omitted from the drawings, but, the
configuration of this embodiment of the present invention is such
that the lower frame 11 is elevated.
In addition, on the plate bending machine 1, a back gauge 17 which
positions the workpiece 44 in the front-to-back direction (in FIG.
2, the left-to-right direction: the Y axis direction) is provided
with free positional movement in the front-to-back direction. A
plurality of sensors 19 are mounted in various positions on the
back gauge 17 to detect contact with the workpiece 44. The sensors
19 are linear transducers with a comparatively long measurement
stroke, similar, for example, to a direct acting potentiometer.
As a result of the above configuration, when the workpiece 44 is
positioned by contact with the back gauge 17 previously positioned
by a usual means, a determination is made as to whether or not the
outputs of the sensors 19 in a plurality of positions match the
prescribed output values. By this means it is known whether or not
the edge of the workpiece 44 is parallel to the bending line of the
upper and lower dies 13, 15 (hereinafter referred to as the bending
axis C). Accordingly, it can be determined whether or not the
workpiece 44 is in the correct position.
The output from the sensor 19 is input to a conventional numerical
control device 21 mounted on the upper frame 9. The numerical
control device 21 controls the operation of each working section of
the plate bending machine 1 and the operation of the back gauge 17,
as well as the operation of the manipulator 3. The output signals
from the sensors 19 are input to the numerical control device 21 so
that the operation of the manipulator 3 is controlled, and the
output values of the sensors 19 reach the desired output values. In
the present invention, the manipulator 3 is mounted on a base plate
23 which is integrally installed on the freely elevatable lower
frame 11.
More specifically, the base plate 23 extends in the lateral
direction (X-axis direction) along the longitudinal direction of
the lower die 15. A first transfer block 25 is supported in a
freely movable manner along the X-axis on the front surface of the
base plate 23. A pinion (omitted from the drawings) which engages a
rack rod 27 in the X-axis direction mounted on the base plate 23 is
mounted in a freely rotatable manner on the first transfer block
25. A first servo motor 29 is provided for rotatably driving the
pinion. The power transmission system by which the first servo
motor 29 drives the pinion may be any normal configuration. A
detailed explanation is therefore omitted. The first servo motor 29
may be, for example, a stepping motor or the like, and is provided
with a position sensing device such as an encoder.
As a result of the above configuration, the first transfer block 25
can be moved in the X-axis direction by the operation of the first
servo motor 29, and the position of the first transfer block 25
when moving in the X-axis direction can be detected by the position
sensing device.
As is clearly shown in FIG. 1 and FIG. 2, a fan-shaped section 31
is provided, extending in the longitudinal, direction (Y-axis
direction) of the top section on the first transfer block 25. An
arc-shaped rack member 33 is provided on the top of the fan-shaped
section 31. A second transfer block 35 which is freely movable in
the Y-axis direction along the rack member 33 is supported on the
rack member 33. A pinion (omitted from the drawings) which engages
the rack member 33 is provided in a freely rotatable manner, and a
second servo motor 37 which rotatingly drives this pinion is
installed on the second transfer block 35. The second servo motor
37 is provided with a position sensing device such as an encoder in
the same way as with the first servo motor 29.
As a result of the above configuration, the second transfer block
35 is moved in the Y-axis direction in an arc along the rack member
33 driven by the second servo motor 37. The position of the second
transfer block 35 in the Y-axis direction is detected by means of
the position sensing device provided on the second servo motor
37.
As is clearly shown in FIG. 1 and FIG. 2, an elevating brace 39
which is freely movable in the vertical Z-axis direction is
supported on the second transfer block 35, perpendicular to the
direction of movement of the second transfer block 35. A rack is
formed on in the vertical direction on the elevating brace 39. The
pinion (omitted from the drawings) which engages this rack is
supported in a freely rotatable manner on the second transfer block
35, and a third servo motor 41 is mounted on the second transfer
block 35 in a manner to rotatably drive this pinion. The third
servo motor 41 is provided with a position sensing device in the
same way as with the second servo motor 37.
As a result of the above configuration, the elevating brace 39 is
activated vertically, driven by the third servo motor 41, and the
vertical position of the elevating brace 39 is known from being
detected by the position sensing device.
An arm 43 extending in the Y-axis direction is suitably secured to
the upper part of the elevating brace 39. A plate clamping device
45 is mounted on the tip of the arm 43 in a manner to freely grasp
one side edge section of the workpiece 44. More specifically, as
shown in FIG. 1 and FIG. 2, the plate clamping device 45 is
provided in a manner to freely rotate in the vertical direction
around a shaft B which is parallel to the X-axis. The plate
clamping device 45 is also capable of freely rotating around a axis
A which is perpendicular to the axis B.
A fourth servo motor 47 for rotating the plate clamping device 45
around the axis A, and a fifth servo motor 49 for rotating the
plate clamping device 45 vertically around the axis B, are mounted
on the arm 43. The fourth and fifth servo motors 47, 49 are each
provided with a position sensing device in the same way as with the
first servo motor 29. In addition, various types of mechanisms can
be adopted as a power transmission mechanism for rotating the plate
clamping device 45 around the axis A by means of the fourth servo
motor 47, and as a power transmission mechanism for rotating the
plate clamping device vertically by means of the fifth servo motor
49. Because these mechanisms have no special features a detailed
description is omitted.
As indicated in more detail in FIG. 3 and FIG. 4, the plate
clamping device 45 is provided with an upper jaw 51 and a lower jaw
53 for grasping the workpiece 44. The upper jaw 51 and the lower
jaw 53 are formed with a wide width plate clamping section 54 which
clamps the workpiece 44, to have an almost T-shape. The jaws 51, 53
are supported in a freely reversing manner on a freely rotating
sleeve 55 which rotates around the shaft B.
More specifically, the rotating sleeve 55, as clearly shown in FIG.
3, is positioned in a crevice-shaped concave section 56 formed at
the tip of the arm 43. A pair of stub shafts 57 are provided, one
on each side of the rotating sleeve 55 on the same centerline as
the shaft B. Specifically, the rotating sleeve 55 is supported in a
freely rotating manner on the tip of the arm 43 through the medium
of the pair of stub shafts 57. Further, a chain sprocket or the
like (omitted from the drawings) is provided on one of the pair of
stub shafts 57. The chain sprocket receives motive power from the
fifth servo motor 49.
As is shown in detail in FIG. 4, a tube 59 rotating in a direction
at right angles to the shaft B is supported in a freely rotating
manner through the medium of a plurality of bearings 61 on the
inside of the rotating sleeve 55. The centerline of the rotating
tube 59 coinsides with the axis A. The lower jaw 53 is integrally
mounted on the upper end of the rotating tube 59. A bevel gear 63
which receives motive power from the fourth servo motor 47 is
integrally mounted on the rotating tube 59.
A linear motion type actuator 65 such as, for example, a cylinder
actuator or the like is provided in the interior of the rotating
tube 59. More specifically, a cylinder 67 is provided with free
vertical activation. The upper jaw 51 is integrally mounted on the
top of the cylinder 67. A vertical two-stage pressure chamber
comprising a chamber 71A and a chamber 71B is formed by a dividing
wall 69 inside the cylinder 67. The chambers 71A, 71B are engaged
by a plurality of pistons 75 mounted on a piston rod 73 and are
connected by a fluid channel formed in the piston rod 73. The lower
part of the piston rod 73 is integrally mounted on a rod holder 77
which in turn is integrally mounted on the rotating sleeve 55.
In order to control the relative rotary motion of the upper jaw 51
and the lower jaw 53, the upper jaw 51 and the lower jaw 53 are
mutually linked through the medium of a link mechanism 79.
Specifically, as is clearly shown in FIG. 4, the end of a first
link 81 of which the base is pivotally supported on the upper jaw
51, and the end of a second link 83 of which the base is pivotally
supported on the lower jaw 51, are linked in a pivotally supported
manner through a pin 85.
As a result of the above configuration, the upper jaw 51 can move
up and down through the action of the actuator 65 and the workpiece
44 can be clamped between the upper jaw 51 and the lower jaw 53.
Because the actuator 65 is provided with the upper and lower
pressure chambers 71A, 71B, a comparatively large clamping force
can be obtained even with a short stroke.
The upper and lower jaws 51, 53 can be rotated around the axis A,
driven by the fourth servo motor 47. As shown in FIG. 3, the plate
clamping section 54 can be positioned in the longitudinal direction
of the arm 43 as well as being positioned projectingly in the
direction of both sides. Accordingly, when the plate clamping
section 54 is in the state where it projects to the sides of the
arm 43, the upper and lower surface of the workpiece 44 which is
clamped in the plate clamping section 54 are reversed by the
rotation of the rotating sleeve 55 around the shaft B.
Moreover, in the bending state on the workpiece 44 being bent by
the upper and lower dies 13, 15, the plate end section clamped by
the manipulator 3 can, for example, move upward with the plate
clamping device 45 following this movement. Specifically, during
processing, corresponding to the movement of the workpiece 44, the
elevating brace 39 is elevated and the plate clamping device 45 is
rotated downward around the shaft B.
Again referring to FIG. 1, an auxiliary clamping device 87 which
freely grasps the workpiece 44 temporarily is mounted on one side
section cf the base plate 23 or the lower frame 11, and a side
gauge device 89 is suitably mounted through the medium of a
bracket.
An upper jaw 91 and a lower jaw 93 are provided on the auxiliary
clamping device 87 to grasp the workpiece 44. The vertical movement
of the upper jaw 91 is carried out in the same way as with the
actuator 65 in the plate clamping device 15, by means of an
actuator (omitted from the drawings). Accordingly, a detailed
description of the action of the upper jaw 91 is omitted.
The side gauge device 89 is provided with a side sensor 95 and is
used to detect the positional relationship of one side of the
workpiece 44 which is clamped by the manipulator 3 and the plate
clamping device 45. The side sensor 95, comprises a linear
transducer such as a direct acting potentiometer, in the safe way
as the sensor 19 provided on the back gauge 17. The output value of
the side sensor 95 is input to the numerical control device 21.
Accordingly, when one side edge of the workpiece 44 clamped in the
plate clamping device 45 contacts the side sensor 95, and when the
output value of the side sensor 95 is the stipulated output value,
the position of the manipulator 3 in the direction of the X-axis is
read by the numerical control device 21 from the detected value of
the position detector device provided on the first servo motor 29.
By comparing the detected value with the position output value of
the base position when the workpiece 44 is not being clamped, the
positional relationship in the X-axis direction of the side edge of
the workpiece 44 clamped in the workpiece clamping device 45 and
the manipulator 3 can be determined. Accordingly, with the side
gauge device 89 as the base, the positioning of the X-axis
direction of the workpiece 44 with respect to the upper and lower
dies 13, 15 can be accurately performed.
As a result of the above configuration, as shown in FIG. 5, when
the plate clamping device 45 is clamping the side S of a
rectangular workpiece 44, the other three sides, T, U, V can be
positioned with respect to the bending axis C by rotating the plate
clamping device 45 around the axis A. Accordingly, it can be
understood that the bending process on the three sides T, U, V can
be performed consecutively. In addition, as shown in FIG. 5, when
the plate clamping device 45 projects to the side of the arm 43,
the workpiece 44 can be reversed in the vertical direction by
rotation around the shaft B. Specifically, even the reverse bending
of the workpiece 44 can be performed in sequence.
As outlined above, after the three sides T, U, V of the workpiece
44 have been bent, to bend the side S, as shown in FIG. 6 and FIG.
7, with the side U of the workpiece 44 interposed between the upper
and lower dies 13, 15, as shown in FIG. 8 and FIG. 9, the workpiece
clamping device 45 is moved to the T side or the V side, and the
clamping of the workpiece 44 is improved. Then, by positioning the
S side of the workpiece 44 on the bending shaft C, the bending of
the side S can easily be carried out.
Furthermore, in the difficult case of improving the clamping when
the workpiece 44 is interposed between the upper and lower dies 13,
15 and the dimensions of the workpiece 44 are comparatively small,
the workpiece is moved to the position of the auxiliary clamping
device 87, and the clamping of the workpiece 44 can be easily
improved by temporarily clamping the workpiece 44 with the
auxiliary clamping device.
Again referring to FIG. 1, a control device 97, such as a computer,
for controlling the plate bending machine 1 and the manipulator 3
and the like through the numerical control device 21 is provided.
The control device 97 comprises a central processing unit (CPU) 99,
a display device 101, and a keyboard 102.
Also, the control device 97 is so constructed as to be capable of
receiving data from storage mediums 100a, 100b, such as floppy
disks, for controlling the CPU 99. The storage mediums comprise a
system instruction storage medium 100a for storing instructions for
the basic system of the control device 97, and a bending parameter
storage medium 100b for storing bending parameters corresponding to
a specific shape of a product. Here, the bending parameter storage
medium 100b is prepared for each shape of product (however,
parameters corresponding to the dimensions of the products is
stored as free parameters). Therefore, the storage mediums are
prepared as much as the number of desired shape of the
products.
Now, referring to FIG. 10, in the numerical control device 21 or
the CPU 99, first means for controlling the manipulator 3 in
response to a signal from the sensor 19 of the backgauge 17 (as the
plate position detection means) is provided to position the
workplate W in Y-axis direction as shown in FIGS. 11a, 11b and
11c.
More specifically the first control means 106 comprises an object
position setting means 107, a spacing calculation means 108, a
spacing reduction ratio setting means 109, a spacing reduction
value calculation means 111, an allowable value setting means 113,
a spacing and allowable value comparison means 115, and a counter
117.
The object position setting means 107 sets an object position of
the rear end edge of the plate where the positioning of the plate
in Y-axis direction is performed. Here, the object position is
represented by a projecting lengh OFFY of the sensor 19 as shown in
FIGS. 11a, 11b, and 11c.
The spacing calculation means 107 first calculates the spacing D1,
D2 for the current position, SX, DEX, and the object position OFFY
of the right and left rear end edges of the plate when either one
of the rear end edges touches the sensors 19, as shown in FIG. 11b.
Then, the means 107 calculates the angle ALFA formed between the
rear end edge W1 and bending axis C, and mean spacing YM as
follows: ##EQU1## where DEFF (=D1-D2=) SX-DEX and LUN is the length
of the workpiece W in the direction of the bending axis. Here it
should be noted that the value of the angle ALFA is approximately
equal that of the tangent thereof when it is represented by the
radian unit because ALFA<<1.
The spacing reduction ratio setting means 109 sets the ratio KGY,
KGA for which the spacing YM, ALFA calculated by the spacing
calculation means 107 is reduced by movement of the manipulator 3.
This ratio KGY, KGA has an value smaller than unity such as 1/2,
1/3 or the like.
The spacing reduction value calculation means 111 multiplies the
ratio KGY, KGA with the spacing YM, ALFA respectively to calculate
the amount of linear movement of the manipulator 3 along Y-axis
direction IAY and the amount of rotational movement thereof about
A-axis IAA:
The allowable value setting means 113 sets the value YS, DIFFS
allowed as the error for the positioning of the workpiece W in
terms of the spacing YM and DIFF.
In addition, the spacing and allowable value comparison means 115
compares the spacing YM, DIFF and the allowable value YS, DIFFS and
generates a signal when YM, DIFF is smaller than YS, DIFFS.
The counter 117 counts the number of times K in which the value YM,
DIFF is smaller than the allowable value YS, DIFFS, and when this
exceeds a specified value N, it outputs a positioning action stop
signal to the spacing calculating means 108 spacing reduction
calculator means 111 and manipulator 3.
A manipulator drive control section 119 drives and controls the
manipulator 3 based on instructions from the spacing reduction
value calculation means 111 and the counter 117.
Accordingly, as a result of this configuration, the workpiece W
which is clamped in the manipulator 3 gradually approaches the
object position (FIG. 11e) from the positioning action start status
(FIG. 11a), through a plurality of approaching steps. And when the
workpiece W approaches the object position through N times of
approaching steps after the spacing YM, DIFF become smaller than
the allowable value YS, DIFFS, it is assumed that the positioning
has been completed with adequate accuracy, and the workpiece is
stopped in that position (FIG. 11c).
Now referring to FIG. 12, in the numerical control device 21 or in
the CPU 99, a second means 123 for controlling the manipulator 3 in
response to a signal from the side sensor 95 of the side gauge
device 89 is provided to position the workpiece W in the X-axis
direction as shown in FIGS. 13a, 13b and 13c.
More specifically, the second control means 123 comprises a side
sensor standard position setting means 125, an side sensor
displacement detection means 127, a plate-clamping-device position
detection means 129, a clamping position calculation means 131, and
a plate position calculation means 133.
More specifically, the side sensor standard position setting means
125, as shown in FIG. 13a, in the status where the workpiece W does
not touch the side sensor 95, allots the distance QFREE from the
center position 0 of the dies 15, 17 to the tip of the side sensor
95.
The side sensor displacement detection means 127, as shown in FIG.
13b, detects the amount of displacement SIDG of the side sensor 95
in the case where the workpiece W touches the side sensor 95.
The plate-clamping-device position detection means 129 calculates
the distance XA from the center position of the die 15 to the
A-axis of the plate clamping device 45, based on the signal from a
position detection device provided on the first servomotor 29, as
shown in FIG. 13b.
Then, the clamping position calculation means 131 calculates the
distance DELSID=QFREE+SIDG-XA between the plate side edge W2 and
the A-axis of the plate clamping device, as shown in FIG. 13b,
based on the distance QFREE, SIDG, XA. Also, based on the distance
DELSID and the distance L/2 between the plate side edge W2 and the
plate centerline 0', as shown in FIG. 13b, the distance between the
plate centerline 0' and the A-axis,
is calculated.
The plate position calculation means 133 calculate the distance
X+XA, from the centerline 0' of the workpiece W to the center
position of the die 15, as shown in FIG. 13c, based on the output
of the plate position calculation means 133.
Accordingly, the manipulator 3 is moved by a suitable amount in the
X-axis direction through the manipulator drive control section 119,
and the centerline 0' of the workpiece W coincides with the
centerline 0 of the dies 13, 15, so that the workpiece W is
positioned in the X-axis direction.
Next, the bending process performed using the plate bending device
of this embodiment of the present invention will be explained with
reference to FIGS. 14a, b, and c through FIG. 19. Now referring to
FIGS. 14a, b, and c, one example of a product manufactured by the
plate bending process of the present invention is demonstrated, for
example, in the flanged boxes 133, 135, and 137. It is to be noted
that the shape of the boxes in FIGS. 14a, b, and c is indicated by
cross-sectional diagrams in both the longitudinal and lateral
directions. Specifically, on a box 133 shown in FIG. 14a a
plurality of flanges 133b, 133c, 133d, 13e are formed, bent upward
at 90 deg with respect to the bottom 133a, and a flange 133e is
formed, bent downward 90 deg. On a box 135 shown in FIG. 14b a
plurality of flanges 135b, 135c, 135d, 135e are formed, bent upward
and inward at 90 deg each in two stages with respect to the bottom
135a. On a box 137 shown in FIG. 14c a plurality of flanges 137b,
137c, 137d, 137e are formed, bent upward and inward at 90 deg each
in two stages with respect to the bottom 137a, after which these
flanges are again bent upward at 90 deg.
Next, an outline of the bending process for the box will be
explained with reference to FIGS. 15a to 15z.
First, the workpiece W is taken from the magazine section 5, the
short side is inserted between the upper die 13 and the lower die
15 (FIG. 15a), and a flange 139 is processed (FIG. 15b).
Next, the short side of the workpiece W is again inserted between
the upper die 13 and the lower die 15 (FIG. 15c) and a second
flange 141 is processed (FIG. 15d).
Then, the jaws 51, 53 are rotated 180 deg around the A-axis (FIG.
15e) and the short side opposite the short side which was
previously bent is bent twice in succession (FIG. 15f, g, h,
i).
Following this, the jaws 51, 53 are rotated 90 deg around the
A-axis (FIG. 15l), after which the workpiece W is positioned by
means of the side sensor 95, and revision of the height is
performed as required (FIG. 15m).
Next, the free long side is inserted between the upper die 13 and
the lower die 15 and is bent twice in succession (FIG. 15 o, p,
q).
The jaws 51, 53 are then rotated 90 deg around the A-axis (FIG.
15r) and the same long side which is clamped in the jaws 51, 53 is
clamped in the jaws 91, 93 of the auxiliary clamping device 87
(FIG. 15r).
Next, the jaws 51, 53 are temporarily removed from the workpiece W,
are rotated 180 deg around the A-axis, and clamp the long side
which has already been bent (FIG. 15t).
The jaws 91, 93 of the auxiliary clamping device 87 are then
removed from the workpiece W and the jaws 51, 53 are rotated 90 deg
around the A-axis, after which the workpiece W is positioned by
means of the side sensor 95 and revision of the height is performed
as required (FIG. 15u).
Following this, the free long side is inserted between the upper
die 13 and the lower die 15 and is bent twice in succession (FIG.
15v, w, x, y).
Next, the jaws 51, 53 are rotated 90 deg around the A-axis and the
product is discharged to the transport device 7 (FIG. 15z).
Next, the bending process, with emphasis on the positioning of the
workpiece, will be explained in detail with reference to FIG. 16 to
FIG. 19.
In step 143, as outlined above, the workpiece W is withdrawn from
the magazine 5 by the manipulator 3.
In step 145, the workpiece clamping device 45 is rotated around the
A- and B-axes, and the workpiece W is arranged in a specified
standard position.
In addition, as will be explained in detail later, along with
changing of the clamping position of the workpiece and the like,
the workpiece W is positioned in the X-axis direction, as
required.
In step 147, the workpiece W is inserted between the dies 13, 15.
At this time, in order to prevent the workpiece W from impacting
the dies, a specified height is maintained from the lower die 15
and the workpiece W is inserted between the dies 13, 15.
In step 149, as will be explained in detail later, the bending side
of the workpiece W is adjusted to conform to the bending axis c of
the dies 13, 15.
Furthermore, at this time, as shown in FIG. 17a, in the case where
the short side of the workpiece W is being bent, for example, among
the sensors 19 provided on the back gauge 17, one pair of sensors
19 as represented by the coding (1), (2), or (3) is selected, and
the workpiece W is positioned with respect to the dies 13, 15
according to the signal from the selected sensors 19. On the other
hand, in the case where the long side of the workpiece W is to be
bent, as shown in FIG. 17b, one pair of sensors 19 as represented
by the coding (4), (5), or (6) is selected, and the workpiece W is
positioned with respect to the dies 13, 15 according to the signal
from the selected sensors 19.
In step 151, data representing the position of the workpiece W is
modified based on the signal from the sensor 19, as required.
In step 153, in order to perform the bending process, the lower die
15 is moved. In addition, at this time, the manipulator 3 is moved
to follow the movement of the edge of the workpiece W.
In step 155, after the bending process has been carried out, the
workpiece clamping device 45 is returned to a specified base
position.
In step 157, calculations are made to revise the height and width
of the workpiece W. For example, in FIG. 15b, when the first flange
139 has been formed, the length of the workpiece W is decreased by
the height of the flange only, while only the thickness of the
workpiece W is increased, so that calculations are made to revise
this balance.
In step 159, a check is made to determine whether or not the last
bending stage has been performed. If additional bending remains,
the program returns to step 145.
The loop from step 145 to step 159 is continued until all the
bending steps have been performed, and when the final bending step
has been completed, the program proceeds from step 159 to step
161.
In step 161, the finished product is discharged to the transport
device 7 and the bending operation is completed.
Now referring to FIGS. 13, and 18, the operation for positioning
the workpiece W in the X-axis direction in step 145 will be
explained in detail.
In step 163, the determination is made as to whether or not it is
necessary to position the workpiece W in the X-axis direction. For
example, there is the case where the clamped side has been changed,
as previously outlined, or the case where the process is
transferred from bending the short side to bending the long
side.
If the result of this determination is positive, the program
advances to step 165. Here, the workpiece side edge W2 is, for
example, Si=5mm away from the end section of the side sensor 95, as
shown in FIG. 13a.
In step 165, the manipulator 3 is moved in the X-axis direction and
the workpiece W on the side sensor 95 side is transferred under the
rule Si=(1/2)AT2. Here, A is the acceleration of the manipulator 3
moving in the X-axis direction (for example, 700 mm/sec/sec), and I
is the time of movement.
In step 167, a check is made to determine whether the displacement
SIDG (see FIGS. 13a, 13b) of the side sensor 95 is zero or not. If
the result is positive, the side edge W2 of the workpiece W is not
yet touching the side sensor 95, so the program moves to step
169.
In step 169, a check is made to determine whether the position XA
of the manipulator 3 on the X-axis is equivalent to the maximum
possible value XMAX or not. In the case of a positive
determination, this means that the workpiece side edge W2 passes
over or under the edge sensor, or the sensor 95 has broken down.
Therefore, the program proceeds to step 171, the bending process is
interrupted, and an appropriate warning is given.
On the other hand, in the case of a negative determination, the
program returns to step 167, and, while the manipulator 3 is being
moved in the direction of the side sensor 95, a check is made to
determine whether the side sensor displacement SIDG is zero or
not.
Through the repetition of these actions the workpiece side edge W2
is made to touch the side sensor 95, the result in step 167 becomes
negative, and the program proceeds to step 173.
In step 173, the side sensor displacement SIDG is detected, and the
program proceeds to step 175.
In step 175, a check is made to determine whether or not the sensor
displacement SIDG exceeds a specified value SIDO, set close to the
center of the sensor action range. If negative, the program returns
to step 173 and, while the manipulator 3 is moving in the direction
of the side sensor 95, the side sensor displacement SIDG is
detected.
If a positive determination is made at step 175, the program
proceeds to step 177.
In step 177, the movement of the manipulator 3 is terminated.
In step 179, the movement XA of the manipulator 3 on the X-axis and
the displacement SIDG of the side sensor 95 (as shown in FIG. 13b)
are detected.
In step 181, the distance DELSID from the manipulator A-axis to the
workpiece side edge W2 is calculated based on the movement XA and
the displacement SIDG, as well as the distance QFREE from the
center point 0 of the dies to the tip of the free side sensor, as
shown in FIG. 13b :
In step 181, based on the distance DELSID and the distance LUN/2
(where L is the width of the workpiece W in the X-axis direction)
from the centerline 0' of the workpiece to the workpiece side edge
W2, the distance from the centerline 0' of the workpiece to the
A-axis of the manipulator is calculated:
as shown in FIG. 13b.
In step 183, based on the distances XA and X, the manipulator 3 is
moved a distance (XA+X) to coincide with the workpiece centerline
0' or the centerline of the dies 0.
In step 183, by means of a previously obtained parameter, the
workpiece is rotated and reversed or the like by the drive of the
manipulator in the A-, B-, Y-, and Z-axis directions, and is
presented to the dies at a specified bending location.
Further, in step 163, in the case where positioning of the
workpiece W in the X-axis direction is unnecessary, the program
immediately proceeds to step 183 and the manipulator 3 is
driven.
From the abovementioned positioning action in the X-axis direction,
it is possible to provide a product bent with high precision with
an inexpensive manipulator.
In addition, when the workpiece side edge W2 contacts the side
sensor 95, the manipulator 3 is stopped close to the center of the
range of action of the side sensor 95 so that the workpiece W does
not erroneously contact the support member of the side sensor
95.
Next, referring to FIG. 11 and FIG. 19, the process in step 149 for
positioning the workpiece W in the Y-axis direction will be
explained in detail.
In step 185, a variety of settings are performed to prevent the
workpiece W from impacting the back gauge 17 during the previously
mentioned positioning action. First, the back gauge 17 is moved in
the Y-axis direction by an amount corresponding to the width of the
flange to be bent and a space PS (FIG. 11b) between the back gauge
17 and the dies 13, 15 is set at a suitable value.
Second, the standard projecting length OFFY (FIG. 11c) of the
sensor 19 corresponding to the width of the flange to be bent is
set at, for example, 10 mm. As outlined below, the workpiece W is
positioned in Y-axis direction so that projecting lengths SX, DEX
of right and left sensors 19 is equivalent to the abovementioned
standard projecting length OFFY. Accordingly, the standard
projecting length OFFY is also called the object projecting length
hereinafter. The value of the standard projecting length OFFY is
stored in the memory device of the numerical control device 21, for
example.
The workpiece W then approaches the sensor 19 in the Y-axis
direction according to the rule
where Si is the distance from the rear edge of workpiece W to the
tip of the sensor 19, A is the acceleration of the manipulator in
the Y-axis direction (for example, 1700 mm/sec2), and T is the
elapsed time.
In step 187, a check is made to see whether or not the projecting
length SX of the left sensor 19 is equivalent to its maximum value
SXO (FIG. 11a). From this check a judgement is made as to whether
or not the rear side of the workpiece W is touching the left sensor
19. If affirmative, the rear side of the workpiece W is not
touching the left sensor 19, and the program proceeds to step
189.
In step 189, a check is made to see whether or not the projecting
length DEX of the right sensor 19 is equivalent to its maximum
value DXO (FIG. 11a, FIG. 11b). If affirmative, the rear side of
the workpiece is not touching the right sensor 19, and the program
proceeds to step 191.
In step 191 a check is made to see whether or not the manipulator 3
is fully moved to the rear end in the X-axis direction and its Y
coordinate is equivalent to its maximum value YMAX. If affirmative,
this means that there is an abnormality. For example, the workpiece
W and the sensor 19 have missed each other or the sensor 19 itself
is defective. The program therefore proceeds to step 193 and a
suitable alarm is given that the bending process has been
interrupted.
On the other hand, if a negative decision is obtained in step 191,
the program return to step 187 and the previous process is
repeated.
If this happens, in due course the rear end on either the right or
left side of the workpiece W contacts the sensor 19, and if in
either step 187 or step 189 a negative decision is obtained the
program proceeds to step 195.
In step 195, the values SX, DEX of the projecting length of the
left and right sensors 19 are stored in a suitable memory
device.
In step 197, the parameters DIFF, D1, D2, ALFA, and YM which are
required for subsequent positioning actions, are calculated.
As shown in FIG. 11b, the parameter DIFF is the difference between
the projecting lengths SX and DEX of the left and right sensors 19,
given by the equation:
It should be noted that when the workpiece W is inserted between
the dies 13, 15 this difference DIFF is not necessarily zero
because the positioning precision of the manipulator 3 is not that
high. As shown below, by means of the positioning procedures, this
difference is made substantially zero, and the rear end of the
workpiece is placed parallel to the bending axis C.
As shown in FIGS. 11a, 11b, the parameter D1 is the difference
(hereinafter referred to as the spacing) between the standard
projecting length OFFY and the current projecting length SX of the
left sensor 19, given by the equation:
In the same way, the parameter D2 is the difference between the
standard projecting length OFFY and the current projecting length
DEX of the right sensor 19, given by the equation:
Now, the parameter ALFA (.alpha.) is the tangent of the angle
produced when the rear end of the workpiece W is misaligned with
respect to the bending axis C of the dies 13, 15, given by the
equation:
where LUN is the length of the workpiece W in the direction
parallel to the bending axis C. Here it should be noted that the
angle of misalignment (i.e. the value of ALFA) is usually small.
Accordingly, the parameter ALFA also represents the misaligned
angle itself.
The parameter YM is the arithmetical mean of the gaps, D1, D2,
given by:
In step 199, a check is made to see whether or not the parameter YM
is greater than the allowable value YS. If affirmative, the
positioning of the workpiece W is insufficient so that program
proceeds to step 201 and the counter value K is set to zero.
If a negative decision results in step 199, the program proceeds to
step 203 and a check is made to see whether or not the parameter
DIFF corresponding to the parameter ALFA is greater than the
allowable value DIFFS. If the decision is affirmative the
positioning of the workpiece W is insufficient and the program
proceeds to step 201, where the counter value K is set to zero, the
same way as in step 199.
In step 204, the amount of movement IAY of the workpiece clamping
device 45 in the Y-axis direction for moving the workpiece W to the
position where the positioning of the workpiece W is made, is
calculated by the equation
Here, the coefficient KGY is set at a value smaller than 1, such as
1/2, 1/3, and the like. For example, if KGY=1/2, the workpiece
clamping device 45 is moved in the Y-axis direction to reduce the
spacing YM in half.
In step 205, in the workpiece positioning cycle for bending a
specified flange, a check is made to see whether or not this is the
first positioning action. If a positive decision is obtained, the
program proceeds to step 207, and the amount of movement IY of the
workpiece clamping device 45 is determined to be IY=IAY and the
program proceeds to step 211.
If a negative determination results in step 205, this means that
this step is the second or a subsequent action in the positioning
cycle, so the program proceeds to step 209.
Then, the amount of movement IY of the workpiece clamping device 45
is calculated by adding the previous amount of movement IY and the
present amount of movement IAY as follows: IY=IY+IAY. Then the
program proceeds to step 211.
In step 211 in the same way as before, the new position of the
workpiece clamping device 45 is determined to be Y=Y0+IY. Here, Y0
is the original position of the workpiece clamping device 45 at a
time when the workpiece W is first inserted between the dies 13,
15.
In steps 213 to 221, positioning calculations similar to those
performed in steps 204 to 211 are made to correct the positioning
misalignment of the workpiece around the axis A.
Specifically, in step 213, the parameter ALFA is multiplied by a
coefficient KGA which is less than 1, and the amount IAA to rotate
the workpiece clamping device 45 around the shaft A is calculated
as follows:
In step 215, the determination is made as to whether or not this is
the first positioning action around A-axis, concerning a specified
flange bending. If positive, the program proceeds to step 217 where
the amount of rotation IA of the workpiece clamping device 45 is
determined to be IA=IAA. A negative decision in step 215 directs
the program to step 219 where the previous amount of rotation IA is
added and the present amount of rotation IA is determined to be
IA=IA+IAA.
In step 221, the value of IA determined in step 217 or step 219 is
added to the original rotational position A0 of the workpiece
clamping device 45 to give a new rotational position A:
In step 223, the workpiece clamping device 45 is moved to position
Y in the Y-axis direction determined from steps 204 to 211, and the
rotary position A determined from steps 213 to 221 (FIG. 11b).
Subsequently, the abovementioned steps are repeated so that the
parameters YM, DIFF become smaller than the respective allowable
values YS, DIFFS.
When the parameters YM, DIFF become smaller than the respective
allowable values YS, DIFFS, the program proceeds from step 203 to
step 225.
In step 225, the value of the counter K is incremented and the
program proceeds to step 227.
In step 227, a check is made to see whether or not the value of the
counter K is equal to a previously set specified value N. If this
value has not been reached, the program returns to the loop
consisting of the steps 204 to 223, and the abovementioned
positioning actions are once again performed.
While these actions are being repeated, the value K in the counter
reaches the specified value N, and the program proceeds from 227 to
229, the value K of the counter returns to zero, and the cycle of
the workpiece clamping device in the Y-axis direction terminates
(FIG. 11c).
In the above embodiment of the present invention, because the
workpiece W is finally placed in a position separated by OFFY from
the back gauge 17, there is no concern that the workpiece W will
impact the back gauge 17 during the positioning action.
Moreover, it is possible to end this positioning cycle, for
example, in the order of 40/1000 seconds. Also, it is possible to
perform the positioning with a precision of about 1/100 mm.
On the other hand, before positioning automatically, it is
necessary to adequately compensate for the offset of the sensor 19
in the same way as for other equipment.
As can be understood from the foregoing explanation, in the present
invention, because the manipulator is driven and controlled by
means of the signal from the action of positioning the workpiece, a
high precision bending process can be performed by a manipulator
which itself does not have a high degree of positioning
precision.
As a result it is possible to construct a relatively inexpensive
manipulator.
* * * * *